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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 1.6L SOHC Engine >> 1.6L SOHC >> Removal >> Removal - Engine Assembly

Removal - Engine Assembly

Fig 1: Air Cleaner Housing
GC0021466Courtesy of DAIMLERCHRYSLER CORP.
  1. Perform fuel pressure release procedure (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) .
  2. Remove throttle body air inlet hose and air cleaner housing assembly.
    Fig 2: Battery Removal/Installation
    GC0021162Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY
  3. Disconnect battery cables and remove battery (1).
    Fig 3: Battery Tray Removal/Installation
    GC0021163Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY TRAY
  4. Remove battery tray (1).
  5. Drain cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .
  6. Discharge air conditioning system, if equipped (Refer to HEATING & AIR CONDITIONING - STANDARD PROCEDURE) .
  7. Disconnect engine wiring harness at Powertrain Control Module (PCM).
    Fig 4: PDC Bracket Attaching Bolts
    GC0021164Courtesy of DAIMLERCHRYSLER CORP.
    1 - PDC
    2 - PDC BRACKET BOLTS
    3 - BATTERY TRAY BOLT
  8. Disconnect positive cable from Power Distribution Center (PDC) (1) and ground wire from vehicle body. Remove bolts attaching PDC and set aside.
  9. Disconnect coolant recovery container hose from radiator neck.
  10. Disconnect heater hoses at thermostat housing and heater return tube.
  11. Disconnect wiring connectors at lower battery tray support.
  12. Remove upper radiator support crossmember (Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - REMOVAL) .
  13. Remove upper radiator hose.
  14. Remove lower radiator hose.
  15. Disconnect upper A/C line from A/C condenser.
  16. Disconnect A/C lines at junction near upper torque strut.
  17. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser).
  18. Disconnect transmission shift cables and transmission electrical connectors.
  19. Disconnect brake booster and purge solenoid vacuum hoses.
    Fig 5: Splash Shield
    GC0042373Courtesy of DAIMLERCHRYSLER CORP.
    1 - RIGHT MOUNT BOLT ACCESS PLUG
    2 - FASCIA
    3 - SPLASH SHIELD
    4 - CRANKSHAFT BOLT ACCESS PLUG
  20. Disconnect ground strap at cylinder head.
  21. Remove fasteners holding power steering return line to right engine bracket. Remove fasteners holding power steering reservoir to right engine bracket. Disconnect reservoir hose from power steering pump. Reposition reservoir out of way.
  22. Raise vehicle on hoist.
  23. Drain engine oil.
  24. Remove both front wheels.
  25. Remove accessory drive belt splash shield (3).
    Fig 6: Lower Torque Strut
    GC0021433Courtesy of DAIMLERCHRYSLER CORP.
    1 - PENCIL STRUT
    2 - TORQUE STRUT FASTENERS
    3 - LOWER TORQUE STRUT
  26. Remove accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - REMOVAL) .
  27. Remove pencil strut (1) and lower torque strut (3). See Fig 6.
    Fig 7: Clutch Slave Cylinder/Damper
    GC0021434Courtesy of DAIMLERCHRYSLER CORP.
    1 - DAMPER FASTENERS
    2 - CLUTCH SLAVE CYLINDER FASTENERS
  28. Remove left and right drive axles (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) .
  29. Remove fasteners securing exhaust pipe to exhaust manifold.
  30. Remove clutch slave cylinder and damper fasteners (1,2). See Fig 7. Reposition and support with suitable strap.
  31. Disconnect power steering pressure line from power steering pump.
  32. Disconnect A/C compressor electrical connectors.
  33. Remove A/C compressor mounting bolts. Remove A/C compressor.
  34. Lower vehicle.
    Fig 8: Positioning Engine - Removal/Installation
    GC0021435Courtesy of DAIMLERCHRYSLER CORP.
    1 - SAFETY STRAPS
    2 - CRADLE 6710
    3 - WOODEN BLOCK
    4 - POST KIT ENGINE CRADLE 6848
    5 - PLACE REAR POSTS INTO LOCATING HOLES
  35. Disconnect fuel line from fuel rail.
  36. Raise vehicle enough to allow dolly 6135, cradle 6710 (2), Post Kit Engine Cradle 6848 (4). For Special Tool identification (Refer to ENGINE - SPECIAL TOOLS)  .
  37. Loosen Post Kit Engine Cradle 6848 (4) to allow movement for positioning onto engine locating holes. See Fig 8. Position wooden blocks (3) under oil pan. Lower vehicle and position cradle until the engine is resting on Post Kit Engine Cradle 6848 (4) and wooden blocks (3). Tighten Post Kit Engine Cradle 6848 (4) mounts to cradle 6710 (2) frame. This will keep Post Kit Engine Cradle 6848 (4) from moving when removing or installing engine and transmission.
  38. Install safety straps (1) around the engine to cradle 6710 (2). See Fig 8. Tighten safety straps (1) and lock them into position.
    WARNING: Safety straps MUST be used to secure engine to the dolly fixture.
  39. Raise vehicle enough to see if safety straps (1) are tight enough to hold cradle 6710 (2) assembly to engine.
  40. Lower vehicle so weight of the engine and transmission ONLY is on the cradle 6710 (2) assembly.
    Fig 9: Engine Mounting - Right Side
    GC0021436Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - RIGHT FENDER
    3 - UPPER TORQUE STRUT BRACKET
    4 - NUTS
    5 - BOLT
    6 - UPPER TORQUE STRUT
    7 - ENGINE MOUNT BRACKET
    8 - BOLT
    9 - LOWER TORQUE STRUT
    10 - BOLT
    11 - RIGHT ENGINE MOUNT
  41. Remove upper torque strut (6). See Fig 9.
  42. Remove right mount through bolt. See Fig 9
    Fig 10: Left Mount & Bolt
    GC0021169Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  43. Remove left mount attaching bolts. See Fig 10.
  44. Continue raising vehicle slowly until engine/transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.
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